Calculation of fabric manufacturing

Calculation of fabric manufacturing

Fabric manufacturing needs a full proof calculation to make a better profit. Every production manager always does calculation to reduce the wastage and make larger profit. Calculation can help to make a cheaper deal with buyer as no one able to do. In this following article I’m going to show you some critical calculation formula which is important to know every textile professional, textile engineer, Professor even a textile student.

Calculation of fabric manufacturing

Calculation of fabric manufacturing

Technical Formula

                                                     Motor pulley diameter
Loom speed = Motor RPM x ——————————-
                                                      Loom pulley diameter

                                               Actual production
Loom Efficiency % = ——————————-x 100
                                          Calculated production

                                           Yarn weight – Dried yarn weight
Moisture Regain % = ——————————————— x 100
                                                       Dried yarn weight

                                              Yarn weight – dried yarn weight
Moisture Content % = ———————————————— x 100
                                                               Yarn weight

                                             Total ends x Tape length in meter
Warp weight in Kg. = ——————————————————
                                                       1693.6 x Warp count

                                      RS in centimeters x Cloth length in meters x PPI
Weft weight in Kg. = ——————————————————————
                                                              4301.14 x Weft count

                                                    EPI                  PPI
Cloth weight in GSM = —————– + —————– x 25.6
                                               Warp count      Weft count

                                              GSM (Grams per sq. meter)
Oz (Ounce) per sq. yard = ——————————————
                                                                        34

Mathematical formula

Total wt. of size on warp = wt. of sized warp – wt. of upsized warp.

The wt. of size to be put on warp = wt. of upsized warp x % of size reqd to be put on warp.

                                            Length of warp in yds
the wt. of upsized warp = ——————————- x no. of ends + wt. of size.
                                                       840 x count

                                                Wt. of size
Wt. of sized warp = —————————— x 100%
                                      Wt. of upsized warp

                                                 Wt. of size
% of size on warp = —————————– x 100%
                                         Wt. of upsized warp

                                                   length of warp in yds
Count of sized yarn = ——————————————- x no. of ends
840 x wt. of sized warp (in lbs)

                                                                                      100
Count of sized yarn = count of upsized yarn x ———————–                                                                                100 + % of size

You may interested to read Terms of fabric Manufacturing and GSM Calculation

If any you have doubt or if you have any complain about this theory or information please let me know by posting a comment. Don’t be hesitates to ask!

Distinguish between rotors & ring spinning frame.

Rotor spinning frame

Spinning is a process where yarn makes from cotton or something else by twisting though spinning frame machine. There are a few types of spinning machine are used around the world but we will discuss about most used machine like rotor spinning frame and ring spinning frame. Every modern machine has history which created by conventional machine. Modern machine is an upgrade version of conventional machine. Remove some unusual parts of machine & using some latest mechanical or electrical technology; speed up the machine and finally got the modern machine.

Ring spinning frame

Ring spinning frame

Rotor spinning frame

Rotor spinning frame

No Rotor Spinning frame No Ring Spinning frame
01 Rotor spinning frame is modern spinning system machine 01 Ring spinning frame is conventional spinning system machine
02 This machine makes yarn by high drafting from sliver. 02 This machine makes yarn by lower pressure than rotor spinning frame from roving.
03 The working speed of rotor spinning frame is faster than ring spinning frame. 03 The working speed of ring spinning frame is lower than ring spinning frame.
04 Usually rotor spinning frame produced lower count yarn. 04 This machine can produce from low count yarn to high count yarn.
05 Basically the raw material of this machine is low quality. Means low grade cotton. 05 Relatively this machine used high grade cotton to produce yarn.
06 Temperature and moisture of cotton should be controlled to produce yarn by rotor spinning frame. 06 No need to control temperature and moisture of cotton to produced yarn by ring spinning frame.
07 Room temperature should be controlled in 20 to 28 C on spinning room. 07 Its better if the room temperature controlled in 28 to 35 C.
08 Only one drafting system is available on this machine so there are now break draft in this machine. 08 Darting system is split in two divisions called main draft and break draft.
09 Twisting and winding process work separately in rotor spinning frame. 09 Twisting and winding process work with each other.
10 Production of rotor spinning frame is more than ring spinning frame. 10 Production of ring spinning frame is less than rotor spinning frame
11 Consumption of electricity is less than ring spinning frame. 11 Consumption of electricity is more than rotor spinning frame.
12 The ratio of breakage yarn is less than ring spinning frame. 12 The ratio of breakage yarn more than rotor spinning frame.
13 Production sound or noise is less than ring spinning frame. 13 Production sound or noise of the machine is more than ring rotor spinning frame.
14 The produced yarn package large. 14 The produced yarn package is small.
15 A few labor or technician can produce or maintain rotor spinning machine. 15 Ring spinning machine required more than ring spinning frame machine.
16 Rotor spinning frame produced balanced yarn. 16 Ring spinning frame produced less balanced yarn.
17 Trash less cotton is perfect for make yarn balanced so always used cotton should less trash cotton. 17 Comparability this machine can produce yarn from maximum amount of trash full cotton.

You may Interested to read What is carding and classification of carding machine?